Note: Descriptions are shown in the official language in which they were submitted.
CA 02227570 1998-01-22
W O 97/44862 PCTrUS97105599
~UEDUCED CROSSTAI~ M ODUL~R OUTLET
Back~round of the Invention:
The present invention relates to connectors. More particularly, the present
invention relates to a connector assembly for use primarily with telecommunication
devices and the like.
Communication system and/or network efficiency is directly dependent upon
the integrity of the connector scheme employed. Such connector schemes include, for
example, standard int~.rf~cl~.s for equipment/user access (outlet connector), tr:ln~mi~qion
means (horizontal and backbone cabling), and ~rlminiqtr~tion/distribution points(cross-connect and p~t~ ing facilities). Regardless of the type or capabilities of the
tr~n.~miq~ion media used for an inqt~ tion, the integrity ofthe cabling infrastructure is
only as good as the p~,lrollllance ofthe individual components that bind it together.
By way of example, a non-standard connector or pair scheme may require that
work area outlets be rewired to accommodate a group move, system change, or an
in~t~ tion with connecting haldw~e whose installed tr~n~mi~qion characteristics are
compatible with an f~xiqtin~ application but are later found to have inadequate
performance when the system is expanded or upgraded to higher tr~nqmiqqion rates.
Accordingly, connecting hardware without ~lopclly qualified design and tr~ncmi~ion
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97/05~99
capabilities, can drain user productivity, compromise system performance and pose a
significant barrier to new and emerging applications.
Reliability, connection integrity and durability are also important
considerations, since cabling life cycles typically span periods of ten to twenty years.
In order to properly address specifications for, and performance of telecommunications
connecting h~.lw~e, it is ~.ler~ ed to establish a mezlnin~ful and accessible point of
reference. The primary references, considered by many to be the i~ ional
benchmarks for commercially based telecommunications components and in~t~ tions,are standards ANSI/TLA/EL~-568-A (/568) Commercial Building Teleco~ lullicationsCabling Standard and 1 50/IEC 1 1801 (/1 1801), generic cabling for customer premises.
Among the many aspects of telecommunications cabling covered by these standards are
connecting hardware design, reliability and trzln~mi~ion pelrollllallce. Accordingly,
the industry has established a common set of test methods and pass/fail criteria on
which performance claims and conl~d~ive data may be based.
To determine connecting haldwal~ performance in a data environment, it is
preferred to establish test methods and pass/fail criteria that are relevant to a broad
range of applications and connector types. Since the relationship between megabits
and megahertz depends on the encoding scheme used, performance claims for wiringcomponents that specify bit rates without providing reference to an industry standard or
encoding scheme are of little value. Therefore, it is in the interest of both
m~nllf~ turers and end users to standardize performance information across a wide
range of applications. For this reason, application independent standards, such as /568
and /1 1801, specify performance criteria in terms of hertz rather than bits. This
information may then be applied to clett?rmine if requirements for specific applications
are complied with. For example, many of the pelrullllance requirements in the IEEE
802.3i(1 QBASE-T) standard are specified in megahertz, and although data is
transmitted at 10 Mbps for this application, test "frequencies" are specified in the
standard (as high as 15 MHz). Tr~n~mi~ion parameters defined in /568 and /1 1801 for
twisted-pair connectors include attenuation, near-end crosstalk ~NEXT) and return loss.
The net effect of these parameters on channel performance may be expressed in
-
CA 02227570 1998-01-22
WO 97/44862 PCTrUS97/05599
signal-to-noise ratio (SNR). For connecting h~L.lw~e, the parameter tnat has been
found to have the greatest impact on SNR is near-end crosstalk.
Several industry standards that specify multiple performance levels of twisted-
pair cabling components have been established. For example, Category 3, 4 and 5
cable and conn~ctin~ haldw~ are specified in both /568 and /1 1801, as well as other
national and regional specifications. In these specifications, tr~ncmi~ion requirements
for Category 3 components are specified up to 16 MHz. Tr~n~mis~ion requirements for
Category 4 components are specified up to 20 MHz. Tr~n~mi~ion requirements for
Category 5 components are specified up to 100 MHz. The category 5 classificationdefines the most severe trz-n~mi~ion requirements specified by national and
in~rn:~tic n~l standards for unshielded and screened twisted-pair cabling.
In order for a twisted-pair connector to be qualified for a given performance
category, it must meet all applicable tr~ncmi~ion requirements regardless of design or
int~ntl~1 use. The rh~llenge of meeting tr~n~mi~ion criteria is compounded by the fact
that connector categories apply to worst case p~;lrollllance. For example, a work area
outlet that meets Category 5 NEXT requirements for all combinations of pairs except
one, which meets Category 3, may only be classified as a Category 3 connector
(provided that it meets all other applicable requirements).
It is recognized that there are numerous ways of achieving electrical balance for
connecting hal-lw~e of the type that is disclosed by the present invention. Several
Cate~ory 5 type outlet connectors are ples~ ly commercially available. These include
Systemax SCS Category 5 Products from AT&T Network Systems, DVO Plus and BIX
Plus from Northern Telecom and the Category 5 ACO outlet from AMP. This list is
only exemplary and is not intended to be a complete listing of Category 5 type products
that are presently commercially available. Accordingly, there is a continlling need for
improved outlet connectors which meet or exceed Category 5 p~lrullllance
requirements in order to satisfy increasing bandwidth requirements of conlll.ullication
systems and networks.
The Systemax SCS Category 5 outlet from AT&T net~vork systems uses a
"cross-over lead" concept which achieves a desired level of crosstalk performance
,
CA 02227~70 1998-01-22
WO 97/44862 PCT~US97/05599
without the use of printed wiring boards or other additional components (US 5,186,647
to Denkm~n et al). This product uses a variation ofthe well known lead-frame outlet
construction that has been in use for many years by numerous companies. Althoughthis approach offers potential cost benefits by minimi7.in~ the quantity and types of
components in the completed assembly, it is limited in several major respects.
It will be appreciated that other methods of balance compensation exist, such asselective parallel runs of circuit traces either in a side-by-side configuration of
overlapping traces placed on adjacent layers of a circuit board. It is also possible to
vary trace thickness in order to achieve a degree of inductive balance correction
between pairs. Another method is to lay a piece of flexible printed circuit ~FPC) on top
of an array of contacts. Selected contacts are electrically connected to portions of
flexible printed circuit (FPC). Some of these methods are disclosed in patent
5,299,956, Brownell. Yet another method of achieving balance between pairs that
employs neither lead-frame or printed circuit construction is to selectively twist wire
leads that exit the back of a conventional modular outlet. However, each of these
methods has its own inherent limitations in terms of repeatability, cost and
performance. For example, passive FPC over lead frame designs include drawbacks
such as resonating crosstalk. Where twisted wire leads are employed, inconsistency is
problematic and cost is high.
~n ITT Cannon modular outlet having reduced crosstalk compri.~es a connector
housing with a contact carrier received therein, which ~u~poll~ a plurality of contacts.
A hinged termination cover is attached to the housing for termin~tin~ a plurality of
wires at one end of the contacts. Using the T568A pin/pair scheme defined in standard
/568, the R4 contact comprises an insulation displacement t~nnin~l connected by a
plate to a modular outlet terminal. The T4 contact com~i~es an insulation
displacement (IDC) terrnin~l connected by a lead to a modular outlet t~nnin~l The T1
contact comprises an insulation displacement terminal connected by a plate to a
modular outlet tennin~l. The Rl contact comprises an insulation ~lispl~ement tPrrnin~l
connected by a plate to a modular outlet termin~l The R3 contact comprises an
insulation displacement termin~l connected by a lead to a modular outlet terminal. The
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97/05599
T3 contact comprises an insulation displacement terminal connected by a plate to a
modular outlet termination. The R2 contact comprises an insulation displacement
termin~l connected by a first lead to a modular outlet termin~l A second lead of the R2
contact extends from one side of the first lead of the R2 contact and tPrmin7,tes in a first
plate of the R2 contact. A third lead of the R2 contact extends from the other side of
the first lead of the R2 contact and tf~ S in a second plate of the R2 contact. The
T2 contact comprises an insulation displacement terrninal connected by a first lead of
the T2 contact to a modular outlet tenninal. A second lead of the T2 contact extends
from one side of the first lead of the T2 contact and termin~t~s in a first plate of the T2
contact. A third lead of the T2 contact extends from the other side ofthe first lead of
the T2 contact and terrnin~tes in a second plate of the T2 contact.
The plate of the R4 contact is disposed over the second plate of the R2 contact
and the plate of the Rl contact is disposed over the first plate of the R2 contact, with a
dielectric sheet disposed therebetween. Accordingly, capacitive coupling is in~ .e~ or
added between the R2 contact and the R4 and Rl contacts. Further, the plate of the Tl
contact is disposed above the second plate of the T2 contact and the plate of the T3
contact is disposed above the first plate of the T2 contact, with the dielectric sheet
disposed therebetween. Accordingly, capacitive coupling is in~lucecl or added between
the T2 contact and the Tl and T3 contacts.
It is important to note that these plates are shunt circuits cormected to the signal
carriers such that electrical current does not pass through the plates in order to allow
the signal to pass from input to output. Such passive capacitive plates suffer from the
known problem of resonating crosstalk, a phenomena believed to result from signal
reflection and/or lack of signal balance.
Tn general, prior art modular outlets also have the following limitations.
Many prior art modular outlets have IDC terminals sequenced in accordance
with the wiring scheme of T568A or T568B of /568. These IDC terrnin~l sequences
require that one of the twisted wire pairs be untwisted and split which has a detrimental
effect on crosstalk performance.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05S99
-6-
The prior art modular outlets, when installed into a panel, cannot be stacked
side by side. In applications where higher outlet density is required, the prior art
arrangements sacrifice space efficiency.
Many prior art modular outlets are in.ctz311~kle into proprietary panel openings,
which limit the outlets' adaptability to various applications.
The prior art modular outlets must be installed into a panel opening from the
rear of the panel. In actual inct~ tions, most users prefer to install a termin~tecl outlet
from the front of the panel.
Many prior art outlets which employ a termination cap require extensive cable
prepaldLion, before a cable can be attached to the termin~tion cap. In general, each
twisted pair must be untwisted. Each of the individual wires must be straightened,
aligned, and if necessary, trimmed, before the cable can be installed onto a tPrmin~tion
cap.
A disadvantage of the ITT outlet is that it requires four discrete housing,
components. The living hinge design has the limitations of restricting material
selection and compromised mechanical integrity.
Known doors for prior art outlets are generally spring loaded whereby they are
not retainable in an open position but only in a closed position. This disadvantage
requires a user to use two hands when inct~llin~ a plug, i.e., one to hold the door open
and the other to install the plug.
Summarv of the Invention:
The above-~liccuccecl and other drawbacks and deficiencies of the prior art are
overcome or alleviated by the modular outlet having reduced crosstalk of the present
invention. The present invention allows outlets to be stacked intim~tely side-by-sid_
thereby achieving a higher outlet density and increased space-efficiency. The present
invention configures the contacts such that the IDC tf rmin~lc are sequentially arranged
whereby none of the twisted wire pairs are split. Moreover, the outlets of the present
invention are inctzlllable into an IEC 603-7 industry-standard panel opening, and are
suitable for a wider range of applications. Perhaps most importantly, the present
-
CA 02227~70 1998-01-22
WO 97/44862 PCTfUS97~S59g
invention is both front- and rear-in~t~ ble. In accordance with the present invention,
the modular outlet comprises a connector housing which supports a plurality of
~ contacts and a termin~tion cap mated to the housing for termin~in~ a plurality of wires
at one end of the contacts. The contacts are positioned on a contact carrier which is
received in the housing.
The connector housing comprises a front panel having a standard modular outlet
opening therein, as is well known, e.g., an 8-position or a 6-position modular outlet
opening. Side, top and bottom panels depend from the front panel. A pair of
cooperating uprights depend from the top panel and termin~te with retaining ledges to
l 0 define a slot for receiving an icon or insert. A panel receiving slot is defined by an
angled upright and an angled surface which leads to an opening, at the top panel. A
resilient panel depends from the rear of the bottom panel and generally fo110ws the
contour thereof. Another panel r~ceivillg slot is defined at the front end of the resilient
panel.
The contact carrier comprises a front generally L-shaped portion receptive to a
standard modular plug and having a plurality of slots therein for receiving the contacts.
The slots are defined in an arcuate recess at the front end of the lower leg portion. The
contact carrier is inserted in the connector housing. A terrnination hlock portion
depends ~c;~ vv~dly from the lower end of the upper leg portion. The t~rmin~tion block
portion includes a plurality of slots at the lower portion thereof for receiving the
contacts. Each of ~ese slots communicate with an opening which extends through the
t~rmin~tion block portion, where corresponding contacts pass through. In one
embodiment, the contact carrier also has a rear extension. The extension has twowindows for receiving locking latches on the tf~rmin~tion cap. The extension has two
proL, .l~ions to apply a degree of retention on two or more wire pairs after t~rmin~tion
cap is engaged. The extension has four other protrusions which provide support to
minimi7e movement at the wire t~rmin~tion point after the t.qrmin~tion cap is engaged.
Prior to insertion of the contact carrier in the connector housing, the contactsmust be installed. Using the T568A standard pin/pair scheme and in accordance with
one embodiment of the present invention, the R2 contact comprises an insulation
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/0~599
displacement connection connected by a lead to a pair of plates which are connected to
a modular outlet connection. The R4 contact co~pn~es an insulation displacement
connection conn~cte~l by a lead to a plate which is conn~cted to a modular outlet
connection. The T4 contact comprises an insulation displ~em~nt connection
connt-ctecl by a lead to a modular outlet connection. The Tl contact comprises an
insulation displacement connection connected by a lead to a plate which is connected to
a modular outlet connection. The Rl contact compri~es an insulation displacementconnection connected by a lead to a plate which is connected to a modular outletconnection. The R3 contact compris~?s an insulation displacement connection
connected by a lead to a modular outlet connection. The T3 contact comprises an
insulation displ~Pn-~nt connection connected by a lead to a plate which is connected to
a modular outlet connection. The T2 contact compricçs an insulation displacementconnection conn~cte(1 by a lead to a pair of plates which are connected to a modular
outlet connection.
It is important that one of the plates of the R2 contact is disposed over the plate
of the R4 contact and the other one of the plates of the R2 contact is disposed over the
plate of the Rl contact, with a dielectric sheet (e.g., MylarTM or KaptonTM) disposed
therebetween. Accordingly, capacitive coupling is in~ ced or added between the R2
and R4 contacts, and between the R2 and Rl contacts. Further, one of the plates of the
T2 contact is disposed below the plate of the Tl contact and the other plate of the T2
contact is disposed below the plate of the T3 contact, with a dielectric sheet (e.g.,
MylarTM or KaptonTM) disposed therebetween. Accordingly, capacitive coupling is
in~ ce~l or added between the T2 and Tl contacts, and between the T2 and T3 contacts.
The plates of the contacts are current carrying. More specifically, current
through these contacts, either from the insulation displacement connection to the
modular outlet connection or vice versa, must travel through the plates which form the
capacitive coupling. This method of achieving a controlled amount of capacitive
coupling between selected contacts allows the modular to meet or exceed Category 5
requirements while concurrently it avoids the problem of resonating crosstallc which
results from signal reflection and/or lack of signal balance. Further, while the modular
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
outlet connections are positioned in accordance with a standard configuration, the
insulation displacement contacts are sequentially positioned, thereby elimin~ting pair
splitting when telminS~ting
This method o~ achieving a controlled amount of capacitive coupling between
selected contacts is an important feature of the present invention, whereby reactive
imbalance between pairs that is caused by certain outlet wiring schemes and wireconnectors is compensated for, by the plates and dielectric sheets, so as to allow the
modular outlet of the present invention to meet or exceed C~ategory S requirements as
described hereinbefore. The benefits of Category 5 devices are well known and are
readily appreciated by one of ordinary skill in the art. The most significant being the
substantial cost savings in using unshielded twisted pair wire where individually
shielded pairs, co-axial or fiber optic cable has been used in the past due to bandwidth
limitations of the unshielded and screened twisted-pair cabling.
It is an important feature of the present invention that while the modular outlet
connections are positioned in accordance with a standard configuration, e.g., T568A,
the insulation displacement connections are configured to improve wiring terrnination.
More specifically, termination connections are sequential. In the standard T568~pin/pair scheme wire pair T2 and R2 are split, i.e., not sequential, thereby requiring that
at least this pair be partially untwisted and that a wire 1 of pair 2 cross-over the pair 1
2~ wires thereby creating additional crosstalk between these pairs and impedance
discontinuity of pair 2 at this terrnin~tion. ~int~ining the integrity of the twisted wire
configuration is significant in high bandwidth applications, e.g., Category 5 or the
emerging ATM standards. In accordance with this objective, the untwisting of
conductors is to be minimi7~A, whereby the termination configuration of the present
invention aids in limiting this problem by elimin~ting the pair split when tPrmin~tin~
The three tier contact configuration taught by the present invention not only
~ m~int~in~ pair coherence and consistent polarity during cable lacing and t~rmins~tion, it
also provides for inductive and capacitive reaction balancing to ensure that coupled
contact elements are integral to the signal current paths. They also provide for parallel
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/OS599
-10-
paths that allow for through current that is proportional to the desired amount of
coupling on an individual contact-by-contact basis.
The termination cap comprises a termination block portion having a row of
wire retaining slots defined by a plurality of teeth. A T-shaped block depends from a
front end of the t~rmin~tion block portion and a jacket retaining block depends from an
opposing rear end of the t~rmin~tion block portion. In another embodiment, two
locking latches secure the t~rmin~tion cap to the contact carrier. Four resilient tabs
captivate individual pairs in individual slots in the termination cap and allow the
cable/termination cap sub assembly to be handled easily before eng~ging said
termin~tion cap with the connector carrier.
Prior art modular outlets which employ terrnination caps require a less efficient
method of in~t~lling cables onto the tel~nin~tion caps. In the prior art instances, the
user must untwist each of the wire pairs in a cable, then he must straighten theindividual wires and kim them, if necessary, so that all the untwisted wires can be
inserted simultaneously into receiving holes on the termination cap. This process
is time-consuming, and is particularly inefficient when a large number of modular
outlets must be installed.
The termination cap in the present invention reduces the amount of cable
plt;paldlion. The user simply separates the twisted pairs in a cable, and inserts each
2~ twisted pair into its corresponding slot. Each twisted pair requires only a partial
untwist so that the individual wires can be placed into their respective slots. Only after
the wircs are positioned, would wire trimming be required.
Once the wires have been inserted into slots of the termination cap and the cable
secured thereto, the wires are cut and are tt-rrnin~ted onto respective insulation
displacement connections. The wires are termin~te-1 by inserting the block into a
channel of the contact carrier, thereby aligning the termin~ion cap with the contact
carrier, and pushing downwardly until the insulation displacement connections displace
the insulation on the wires and electrically connect with the conductive wire, (i.e., a
mass termination). IDC's are also preferably of varying height to reduce the pressure
necessary on the cap by spreading the termination events over a short period of time.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05S99
The invention further includes a shield which provides a single continuous path
for connecting incoming to outgoing shield structures. The shield is particularly suited
for the second embodiment, however can be adapted to the first as well.
A door structure is also included which is resilient and provides a good seal
against the modular opening.
The present invention further comprises an outlet door assembly that is
retainable in both an open and a closed position. In accordance with the presentinvention, the door comprises a pair of mounting arms having inwardly extending
protrusions which are received in notches for ret~ning the door in the closed and open
position. In one embodiment the connector housing has an outwardly extending
protrusion within each of a pair of notches to define the positions for retaining the
protrusions of the door arrns. In another em~odiment a door holder is employed which
has pairs of notches, with one pair of notches receiving the protrusions of the door arms
therein for ret~ining the door in a closed position and another pair of notches receiving
the protrusions of the door arms therein for retaining the door in an open position. In
both embodiments the door includes a channel for receiving an identification icon
therein.
The above-discussed and other features and advantages of the present invention
will be appreciated and understood by those skilled in the art from the following
detailed description and drawings.
Brief Description of the Drawin~s:
Referring now to the drawings wherein like elements are numbered alike in the
several FIGURES:
FIGURE 1 is a perspective view of a modular outlet in accordance with the
prior art;
~ FIGURES 2A and B are perspective views of a modular outlet in accordance
with the present invention wherein FIGURE 2A is taken from the front thereof andFIGURE 2B is taken from the rear thereof;
CA 02227~70 l998-0l-22
W O 97144862 PCT~US97/05599
-12-
FIGURES 3A and B are partially exploded perspective views of the modular
outlet of FIGURES 2A and B wherein FIGURE 3A is taken from the front thereof andFIGURE 3B is taken from the rear thereof;
FIGURES 4A and B are fully exploded perspective views of the modular outlet
S of FIGURES 2A and B wherein FIGURE 4A is taken from the top thereof and
FIGURE 4B is taken from the bottom thereof;
FIGURES 5A and B are views of contacts in an assembled configuration for use
with the modularJack of FIGURES 2A and B wherein FIGURE SA is a perspective
view thercof and FIGURE 5B is an exploded view thereof;
FIGURES 6A and B are perspective views of a contact carrier for use with the
modular outlet of FIGU~ES 2A and B wherein FIGURE 6A is taken from the front
thereof and FIGURE 6B is taken from the bottom thereof;
FIGURES 7A and B are perspective views of a termination cap for usc with the
modular outlet of FIGURES 2A and B wherein FIGURE 7A is taken from the rear
thereof and FIGURE 7B is taken from the front thereof;
FIGURES 8A - D are views of an insert for use with the modular outlet of
FIGURES 2A and B wherein FIGURE 8A is a top view thereof, FIGURE 8B is a
bottom view thereof, FIGURE 8C is an end view thereof, and FIGURE 8D is a side
elevation view thereof;
FIGURE 9 is a front perspective view of two of the modular outlets of
FIGURES 2A and B inserted in a wall plate in accordance with the present invention;
FIGURES 1 OA - C are views of contacts in an assembled configuration, in
accordance with an alternate embodiment, for use with the modular outlet of FIGURES
2A and B wherein FIGURE 1 OA is a front perspective view thereof, FIGURE 1 OB is an
exploded perspective view thereof, and FIGURE 1 OC is a rear perspective view
thereof;
FIGURES 1 1 A and 1 1 B are perspective views of a modular outlet in
accordance with the present invention wherein FIGURE 1 lA is taken from the front
thereof and FIGURE 11 B is taken from the rear thereof,
CA 02227~70 1998-01-22
W 097/44862 PCT~US97/05599
FIGURES 12~ and 12B are partially exploded perspective views of the
modular outlet of FIGURES 1 lA and B wherein FIGURE 12A is taken from the front
thereof and l:;IGURE 1 2B is taken from the rear thereof;
FIGURES 1 3A and 1 3B are ~ully exploded perspective views of the modular
outlet of FIGURES 1 1 A and B wherein FIGURE I 3A is taken from the top thereof and
FIGURE 13B is taken from the bottom thereof;
FIGURES 1 4A and 1 4B are perspective views of a contact carrier for use with
the modular outlet of FIGURES I IA and B wherein FIGURE 14~ is taken from the
front thereof and FIGURE 14B is taken from the bottom thereof;
FIGURE I 4C is a front plan view of the carrier illustrating differing depths ofslots.
FIGURES 1 5A and 1 5B are perspective views of a termination cap for use with
the modular outlet of FIGURES 1 lA and B wherein FIGURE 15A is taken from the
rear thereof and FIGURE 1 5B is taken from the front thereof;
FIGURES 1 6A and 1 6B are perspective views of a modular outlet in
accordance with the present invention wherein FIGURE 16~ is taken from the frontthereof and FIGURE 1 6B is a partially exploded view with the door detached;
FIGUR~S 1 7A-D show various views of the doors of the invention;
FIGURE 18 is a front perspective view of six of the modular outlets of
FIGURES 2A and B inserted in a wall plate in accordance with the present invention;
FIGURE 19 is a perspective view of the shield for the embodiments described
herein,
FIGURE 20 is a partially exploded perspective view of one embodiment of the
invention illustrating the shield in place;
FIGUR~ 21 is a top oriented perspective view of one embodiment of thc
invention with the shield in place;
- FIGURE 22 is a bottom oriented perspective view of FIGURE 21;
FIGURE 23 is a perspective view of the straight embodiment of the invention
illustrated in a broken away wall section;
CA 02227~70 1998-01-22
W O 97/44862 PCT~US91/05599
-14-
FIGURE 24is a perspective view of the embodimcnt of FIGURE 23 removed
from the wall;
FIGURE 25is a perspective partially exploded view of the straight
embodiment;
S FIGURE 26is a perspective view of a modular outlet in accordance with an
embodiment of the present invention;
FIGURE 27is another perspective view of the modular outlet of FIGURE 26;
FIGURE 28 is a side elevational view of the modular outlet of FIGURE 26;
FIGURE 29is a perspective view of thc connector housing used in the modular
outlet of FIGURE 26;
FIGURE 30 is another perspective view o:f the connector housing of FIGURE
29;
FIGURE 31 is a perspective view of the door used in the modular outlet of
FIGURE 26;
FIGURE 32is another perspective view of the door of FIGURE 31;
FIGURE 33 is a perspective view of a modular outlet in accordance with
another embodiment of the present invention;
FIGURE 34 is a side elevated view of the modular outlet of FIGURE 33;
FIGURE 35 is a perspective view of the door used in the modular outlet of
FIGURE 33;
FIGURE 36 is another perspective view of the door of FIGURE 35;
FIGURE 37 is a perspective view of the door holder used in the modular outlet
of FIGURE 33;
FIGURE 38 is a plan view of the door holder of FIGURE 37;
FIGURE 39 is a side elevational view of the door holder of FIGURE 37; and
FIGURE 40 is an end view of the door holder of FIGURE 37.
Description of the Preferred Embodiment:
Referring to FIGURE 1, a subassembly of a modular outlet having reduced
crosstalk in accordance with the prior art is generally shown at 200. Su~assembly 200
CA 02227~70 l998-0l-22
W O 97/44862 PCTAJS97/05599
-15-
comprises a connector housing 202 with a contact carrier 204 received therein, which
supports a plurality of contacts 206. A hinged termin~tit~n cover 208 is attached to
housing 202 for termin~tin~ a plurality of wires at one end of contacts 206.
Contacts 206 comprise eight contacts 210, 212, 214, 216, 218, 220, 222 and
S 224. Contact 210 comprises an insulation displacement terminal 226 connected by a
plate 228 to a modular outlet terminal 230 (i.e., pin 8, R4 in accordance with T568A).
Contact 212 comprises an insulation displacement terminal 232 connected by a lead
234 to a modular outlet terminal 236 (i.e., pin 7, T4 in accordance with TS68A).Contact 214 comprises an insulation displacement terminal 238 connected by a plate
240 to a modular outlet terminal 242 (i.e., pin S, T1 in accordance with T568A).Contact 216 comprises an insulation displacement terminal 244 connected by a plate
246 to a modular outlet terminal 248 (i.e., pin 4, R1 in accordance with T568A).Contact 218 comprises an insulation displacement t~rminAI 250 connected by a lead
252 to a modular outlet t~rmin~l 254 (i.e., pin 2, R3 in accordance with TS68A).Contact 220 comprises an insulation displacement terrninal 256 connected by a plate
258 to a modular outlet termination 260 (i.e., pin 1, T3 in accordance with T568A).
Contact 222 comprises an insulation displacement terminal 262 connected by a lead
264 to a modular outlet t~rmin~l 266 (i.e., pin 6, R2 in accordance with T568A). A
lead 268 extends from one side of lead 264 and tçnnin~tes in a plate 270. A lead 272
extends from the other side of lead 264 and termin~te~ in a plate 274. Contact 224
comprises an insulation displacement terminal 276 connected by a lead 278 to a
modular outlet terminal 280 (i.e., pin 3, T2 in accordance with T568A). A lead 282
extends from one side of lead 278 and termin~fes in a plate 284. A lead 286 extends
from the other side of lead 278 and termin~tes in a plate 288.
Plate 228 of contact 210 is disposed over plate 274 of contact 222 and plate 246of contact 216 is disposed over plate 270 of contact 222, with a dielectric sheet 287
(e.g., MylarTM or KaptonTM) disposed therebetween. According, capacitive coupling is
induced or added between contact 222 (i.e., pin 6, R2 in accordance with TS68A) and
contacts 226 (i.e., pin 8, R4 in accordance with T568A) and 216 (i.e., pin 4, R1 in
accordance with T568A). Further, plate 240 of contact 214 is disposed above plate 288
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97/OSS99
-16-
of contact 224 and plate 258 of contact 220 is disposed above plate 284 of contact 224,
with dielectric sheet 287 disposed therebetween. According, capacitive coupling is
induced or added between contact 224 (i.e., pin 3, T2 in accordance with T568A) and
contacts 214 ~i.e., pin 5, Tl in accordance with T568A) and 220 (i.e., pin 1, T3 in
accordance with T568A).
It is important to note that these plates are shunt circuits connected to the signal
carriers such that electrical current does not pass through the plates in order to allow
the signal to pass from input to output. Such passive capacitive plates suffer from the
known problem of resonating crosstalk, a phenomena believed to result from signal
reflection and/or lack of signal balance. This contact arrangement has the additional
disadvantage of requiring that one wire pair such as pair 2 of T568A be t~mlin~ted on
contact positions that are not adjacent and that the positioning of tip and ringconductors are not consistent for all pairs.
The modular outlet of the present invention does not employ such passive
plates, thereby avoiding the problem of resonating crosstaLk. Referring to FIGURES
2A - B, 3A - B, and 4A - B, a modular outlet having reduced crosstalk is shown
gencrally at 10. Modular outlet 10 comprises a connector housing 12 with a contact
carrier 18 received therein, which supports a plurality of contacts 14. A termination
cap 16 mated to housing 12 for t~rmin~ting a plurality of wires at one end of contacts
14.
Connector housing 12 comprises a front panel 20 having a standard modular
outlet opening 22 therein, as is well known, e.g., an 8-position or 6-position outlet
opening as specified in IEC 603-7 and FCC CFR 47, part 68? subpart F. A pair of side
panels 24 and 26 depend rear~vardly from panel 20. Each panel 24 and 26 has
mounting holes 28 and 30 therein. A top panel 32 extends rearwardly from panel 20.
A pair of cooperating uprights 34, 36 terminz-ting with retaining ledges 38, 40 de~me a
slot 42 for receiving an icon or insert 43 (FIGURES 8A - B), as described more fully
hereinafter. A panel receiving slot 44 is defined by an angled upright 46 and an angled
surface 48. A bottom panel 52, opposite top panel 32, extends rearwardly from panel
20. Panel 52 is curved upwardly at the front end thereof. A resilient panel 54 depends
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
from the rear end of panel 52 and generally follows the contour thereof. A panelreceiving slot 56 is defined at the front end of panel 54 and includes inclined surfaces
58, 60 on each side thereofto aid in the insertion and removal of modular outlet 10
f~om and/or to a plate or panel (FI(~U~E 9).
Contact carrier 18 compriscs a front generally L-shaped portion 62 receptive to
a standard modular outlet and having a plurality of slots 64 therein for receiving
contacts 14. Slots 64 are defined in arcuate recess 66 at the front end of the lower leg
portion 68 and in a channel 70 in the front surface of upper leg portion 72. A second
channel 74 is defined in the back surface of upper leg portion 72. The front end of
lowcr leg portion 68 is inclined to cooperate with the curved front end of panel 52
when contact carrier 18 is inserted in connector housing 12. To retain contact carrier
18 within connector housing 12 arms 76, 78 are provided. Arrns 76 and 78 each
include an inclined surface 80 to aid in the insertion of contact carrier 18 in connector
housing 12 from the rear thereof and retaining edges 82. Retaining edges 82 engage
and are received in holes 28 of side panels 24 and 26. A terrnination block portion 84
depends rearwardly from the lower end of leg portion 72. Block portion 84 includes a
plurality of slots 86 at the lower portion thereof for receiving contacts 14. The lower
portion itself comprises three distinct surfaces on three distinct levels for positioning of
contacts. The surfaces are illustrated in Figure 6B and are identified by numerals 85a,
85b, and 85c. Each of the surfaces allow for positioning of desired contacts.
Furtherrnore the surfaces, because they are molded into the carrier itself provide
mechanical stability for the individual contacts in each of the surfaces on which they
are positioned. It should be understood that the slots 64 also include three different
levels of surfaces 85a, 85b and 85c to correspond to those surfaces illustrated in
FIGURE 6B. E~ach slot 86 cornrnunicates with an opening 88 which extends throughblock portion 84, where corresponding contacts 14 pass through. A rarnped surface 90
- defining a retaining ledge 92 is defined at each side 94, 96 of block portion 84. A
recess 98 is defined between block portion 84 and a downward extension 100 of lower
leg portion 68. Recess 98 receives portions of contacts 14 when they are installed on
contactcarrier 18.
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97/05599
-18-
Referring to FIGURES SA - B, prior to insertion of contact carTier 18 in
connector housing 12, contacts 14 must be installed. Contacts 14, in the presentexample, comprise eight contacts 102, 104, 106, 108, 110, 112, 114 and 116. Contact
102 comprises an insulation displacement terminal 118 connected by a lead 120 toplates 122 and 124 which are connected to a modular outlet terrnin~l (i.e., a resilient
wire) 126 (i.e., pin 6, R2 in accordance with TS68A). Contact 104 compri~e.c an
insulation displacement t~rmin~l 128 connected by a lead 130 to a plate 132 which is
connected to a modular outlet t~rmin~l 134 (i.e., pin 8, R4 in accordance with T568A).
Contact 106 comprises an insulation displacement terminal 136 connected by a lead
138 to a modular outlet lermin~l 140 (i.e., pin 7, T4 in accordance with TS68A).Contact 108 comprises an insulation displacement terminal 142 connected by a lead
144 to a plate 146 which is connected to a modular outlet telminal 148 (i.e., pin S, T1
in accordance with T568A). Contact 110 comprises an insulation displacement
terminal l S0 connected by a lead 152 to a plate 154 which is connected to a modular
outlet terminal 156 (i.e., pin 4, R1 in accordance with T568A). Contact 112 comprises
an insulation displacement terminal 158 connected by a lead 160 to a modular outlet
terminal 162 (i.e., pin 2, R3 in accordance with T568A). Contact 114 comprises an
insulation displacement terminal 164 connected by a lead 166 to a plate 168 which is
connected to a modular outlet tellninal 170 (i.e., pin 1, T3 in accordance witl1 T568A).
Contact 116 comprises an insulation displacement terrninal 172 connected by a lead
174 to plates 176 and 178 which are connected to a modular outlet terrninal 180 (i.e.,
pin 3, T2 in accordance with TS68A). Contacts are generally secured in position by
conventional means of ultrasonic welding, swaging, staking, adhesive, etc.
It is an important feature of the present invention, that plate 122 of contact 102
is disposed over plate 132 of contact 104 and plate 124 of contact 102 is disposed over
plate 154 of contact 110, with a dielectric sheet 182 (e.g., MylarTM or KaptonTM)
disposed therebetween. According, capacitive coupling is induced or added between
contact 102 (i.e., pin 6, R2 in accordance with T568A) and contact 104 (i.e., pin 8, R4
in accordance with T568A), and between contact 102 (i.e., pin 6, R2 in accordance
with T568A) and contact 110 (i.e., pin 4, Rl in accordance with T568A). Further, plate
CA 02227~70 1998-01-22
W O 97/44862 PCTAUS97/05S99
-19-
- 176 of contact 116 is disposed below plate 146 of contact 108 and plate 178 of contact
116 is disposed below plate 168 of contact 114, with a dielectric sheet 184 (e.g.,
MylarTM or KaptonTM) disposed therebetween. According, capacitive coupling is
induced or added between contact 116 (i.e., pin 3, T2 in accordance with T568A) and
contact 108 (i.e., pin 5, Tl in accordance with T568A), and between contact 116 (i.e.,
pin 3, T2 in accordance with T568A) and contact 114 (i.e., pin 1, T3 in accordance
with T568A).
It is also an important feature ofthe present invention, that plates 122, 124, 132,
146, 154, 168, 176 and 178 are current carrying. More specifically, current through
these contacts, either from the insulation displacement terrrlin~l to the modular outlet
terminal or vise versa, must travel through the plates which form the capacitivecoupling.
This method of achieving a controlled amount of capacitive coupling between
selected contacts is an important feature of the present invention, whereby reactive
imbalance between pairs that is caused by certain outlet wiring schemes and wireconnectors is compensated ror, by the plates and dielectric sheets, so as to allow the
modular outlet of the present invention to meet or exceed Category 5 requirements as
described hereinbefore without the common problems of resonating crosstalk of
passive plates in the prior art. The benefits of Category 5 devices are well known and
are readily appreciated by one of ordinary skill in the art. The most significant being
the substantial cost savings in using unshielded twisted pair wire where shielded, co-
axial or f1ber optic cable has been used in the past due to bandwidth limitations of the
twisted-pair.
Referring to FIGURES 6A - B, contact 102 is installed on contact carrier 18
with t~rrnin~71 126 disposed in slot 64f, lead 120 disposed in slot 86f, and t~rrnin~l 118
inserted through opening 88f. Contact 104 is installed on contact carrier 18 with
terrninal 134 disposed in slot 64h, lead 130 disposed in slot 86g, and tPrmin~l 128
inserted through opening 88g. Contact 106 is installed Oll contact carrier 18 with
terminal 140 disposed in slot 64g, lead 138 disposed in slot 86h, and terminal 136
inserted through opening 88h. Contact 108 is installed on contact carrier 18 with
CA 02227~70 1998-01-22
W O 97/44862 PCTAUS97/05599
-20-
tçrrnin~l 148 disposed in slot 64e, lead 144 disposed in slot 86e, and ~errnin~l 142
inserted through opening 88e. Contact 110 is installed on contact carrier 18 with
terrnin~l 156 disposed in slot 64d, lead 152 disposed in slot 86d, and terminal 150
inserted through opening 88d. Contact 1 12is installed on contact carrier 18 with
S terrnin~l 162 disposed in slot 64b, lead 160 disposed in slot 86a, and t~rrnin~l 158
inserted through opening 88a. Contact 114 is installed on contact carrier 18 with
terminal 170 disposed in slot 64a, lead 166 disposed in slot 86b, and terrninal 164
inserted through opening 88b. Contact 116 is installed on contact carrier 18 with
terrnin~l 180 disposed in slot 64c, lead 174 disposed in slot 86c, and terrnin~l 180
inserted through opening 88c.
It is an important feature of the present invention that while the modular outlet
terminals are positioned in accordance with a standard configuration, e.g., T568A, the
insulation displacement termin~l~ are configurcd to improve wiring termination. Morc
specifically, sequential terminals 164 and 158 correspond to T3 and R3, respectively;
sequential terrninzll~ 142 and 150 correspond to T1 and R1, respectively; sequential
tçrrnin~l~ 172 and ~ 18 correspond to T2 and R2, respectively; and sequential terminals
136 and 128 correspond to T4 and R4, respectively. In standard T568A tl rrnin~l~ wire
pair T2 and R2 are split, i.e., not sequential, thereby requiring that at least this pair be
partially untwisted at this terrnin~tion. ~int~ining the integrity of the twisted wire
configuration is significant in high bandwidth applications, e.g., Category 5 or the
emerging ~TM standards. In accordance with this objective, the untwisting of
conductors is to be minimi7~ 1, whereby the t~rrninZ~tion configuration of the present
invention aids in limiting this problem by eliminzlting the pair split when terrnin~ting
Referring to FIGURES 7A - B, t~nnin~tion cap 16 comprises a t~rrnin~tion
block portion 182 having a row of wire ret~inin~ slots 184 defined by a plurality of
teeth 186. Teeth 186 include an interior flange 188 which grips a wire by its insulation.
Interior flange 188 has tapered ends 190 to facilitate wire entry. A T-shaped block 192
depends from a front end of termination block portion 182 and a jacket ret~ining block
194 depends from an opposing rear end of t~ in~lion block portion 182. Block 194includes an arcuate recess 196 for receiving the jackct of a cable to be tennin~tell and
CA 02227~70 l998-0l-22
W O 97/44862 PCT~US97/05599
-21-
includes holes 198 and 200 therethrough. The cable being termin~ted is secured to
portion 182 by inserting a cable tie (not shown) through one of the holes, around the
cable, through the other one of the holes, and mating the cable tie, as is well known.
By way of example, in accordance with T568A standards and the improved termination
configuration of the present invention; wire T3 is inserted in slot 184a, wire R3 is
inserted in slot 184b, wire Rl is inserted in slot 184d, wire T1 is inserted in slot 184e,
wire T2 is inserted in slot 184c, wire R2 in inserted in slot 184f, wire T4 is inserted in
slot 184g, and wire R4 is inserted in slot 184h.
Once the wires have been inserted into the slots of the termination cap and the
cable secured thereto, the wires are cut if they extend beyond the slots and the wires are
terrnin~tP-l onto respective insulation displacement termin~lc The wires are tenninz-tecl
by inserting block 192 into channel 74 of contact carrier 18, thereby ~ligning the
t~rrninzl1ion cap with on the contact carrier, and pushing downwardly until the
insulation displacement terminals displace the insulation on the wires and electrically
l S connect with the conductive wire, (i.e., a mass termination). Termination cap l 6 is
retained on contact carrier l 8 by retaining surfaces 200 and associated ramped surfaces
202, with surfaces 200 being engaged in holes 30 of connector housing 12, on top of
the protrusions defined by surfaces 90 and 92 of contact carrier 18. Accordingly, each
hole 30 serves to retain or engage both contact carrier 18, by way of retaining ledges
2û 92, and t~.rmin~tion cap 16, by way of retaining surfaces 200.
Referring to FIGURES 8A - D, insert 43 comprises a pair of opposing surfaces
344, 346 and first and second opposing sides 348, 350. The edges of surfaces 344 and
346 are chamfered. Insert 43 is inserted into slot 42 of connector housing 12 and is
retained therein by friction between these parts. Inserts 43 may include designzltions on
either surface 344 or 346, or be color coded. A computer t~-.rrnin~l 345 is illustrated on
surface 344 (FIGURE 8A) and a telephone 347 is illustrated on surface 346 (FIGURE
8B), by way of example only. It will be appreciated that any ~le~i~n~tion symbol or
term may be molded into or imprinted on these surfaces, as such will be dictated by the
particular application of the modular outlet.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/OS599
-22-
Referring to FIGURE 9~ two modular outlets 10, 10' are shown installed in
corresponding openings 352, 354 of a wall plate 356. Slots 44 and 58 of each of the
modular outlets receive corresponding edges of the wall plated at the openings. As is
clearly shown in this FIGURE, the modular outlets provide for a gravity feed thereto,
the advantages of which are well known, see for example, U.~. Patent No. 5,362,254 to
Siemon et al., which is incorporated herein by reference.
Referring to FIGUR~S lOA - C, in accordance with an alternate and plef~ d
contact configuration. Contacts 14', comprise contacts 102', 104', 106', 108', 1 10', 1 12',
I 14' and 1 16'. Contact 102' comprises an insulation displacement terminal 1 18'
connccted by a lead 120' to plates 122' and 124' which are connected to a modular
outlet t~?nnin~l 126' (i.e., pin 6, R2 in accordance with T568A). Contact 104' comprises
an insulation displacement terminal 128' connected by a lead 130' to a plate 132' which
is connected to a modular outlet terminal 134' (i.e., pin 8, R4 in accordance ~,vith
T568A). Contact 106' comprises an insulation displacement terminal 136' connected
by a lead 138' to a modular outlet tennin~l 140' (i.e., pin 7, T4 in accordance with
T568A). Contact 108' comprises an insulation displacement terminal 142' connected
by a lead 144' to a plate 146' which is connected to a modular outlet terminal 148' (i.e.,
pin 5, T1 in accordance with T568A). Contact 110' comprises an insulation
displacement terminal 150' connected by a lead 152' to a plate 154' which is connected
to a modular outlet termin:~l 156' (i.e., pin 4, R1 in accordance with T568A). Contact
} 12' comprises an insulation displacement lerminz~l 158' connected by a lead 160' to a
modular outlet terminal 162' (i.e., pin 2, R3 in accordance with T568A). C~ontact 114'
comprises an insulation displacement t~rrnin~l 164' connected by a lead 166' to a plate
168' which is connected to a modular outlet terrnin~l 170' (i.e., pin 1, T3 in accordance
with T568A). Contact 116' comprises an insulation displacement terminal 172'
connected by a lead 174' to plates 176' and 178' which are connected to a modular
outlet t~nnin~l 180' (i.e., pin 3, T2 in accordance with T568A).
It is an important feature of the present invention, that plate 122' of contact 102'
is disposed over plate 132' of contact 104' and plate 124' of contact 102' is disposed
over plate 154' of contact 110'~ with a dielectric sheet (e.g., ~ylarTM or KaptonTM)
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97105599
-23-
disposed therebetween. According, capacitive coupling is in~ ce~1 or added between
contact 102' (i.e., pin 6, R2 in accordance with T568A) and contact 104' (i.e., pin 8, R4
in accordance with T568A), and between contact 102' ~i.e., pin 6, R2 in accordance
with TS68A) and contact 110' (i.e., pin 4, Rl in accordance with T568A). Further,
plate 176' of contact 116' is disposed below plate 146' of contact 108' and plate 178' of
contact 116' is disposed below plate 168' of contact 114', with a dielectric sheet (e.g.,
MylarTM or KaptonTM~ disposed therebetween. According, capacitive coupling is
induced or added between contact 116' (i.e., pin 3, T2 in accordance with T568A) and
contact 108' (i.e., pin S, T1 in accordance with T568A), and between contact 116' (i.e.,
pin 3, T2 in accordance with TS6~A) and contact 11 ~' (i.c., pin 1, T3 in accordance
with TS68A~.
As in the other embodiment, it is an important feature of the present invention
that while the modular outlet terminals are positioned in accordance with a standard
configuration, e.g., T568A, the insulation displacement tt?rmin~l~ are configured to
lS improve wiring termination. More specifically, sequential terminals 158' and 164'
correspond to R3 and T3, respectively; sequential terminals 150' and 142' correspond to
R1 and Tl, respectively, sequential terminals 118' and 172' correspond to R2 and T2,
respectively; and sequential terminals 128' and 136' correspond to R4 and T4,
respectively. In standard TS68A t~rmin~l.c wire pair T2 and R2 are split, i.e., not
sequential, thereby requiring that at least this pair be partially untwisted at this
tc.rmin~tion. ~int~ining the integrity of the twisted wire configuration is significant in
high bandwidth applications, e.g., C~ategory S or the emerging ATM standards. Inaccordance with this objective, the untwisting of conductors is to be minimi7~
whcreby the t~rmin~tion configuration of the present invention aids in limiting this
problem by elimin~ting the pair split when termin~ting. Furthermore, in this pl~r~ d
embodiment not only are the corresponding T-R pairs kept together, the specific
alternating T-R sequence is m~int~in~d consistently on all four pairs at the input end.
The input sequence is R3 T3 R1 T1 R2 T2 R4 T4. This has the advantage of not
having T1 and T2 adjacent to each other. Both of these wires are white and could lead
to confusion during in~t~ tion if they were adjacent. This is a benefit to the industry.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
-24-
Referring to FIGURES 1 IA-15B, another embodiment of the mechanical
structure for supporting the electronic members of the modular jack 410 of the
invention is illustrated. A connector housing 412 is adapted to receive a contact carrier
418 which supports a plurality of contacts 414. A termin~tion cap 416 is then mated to
S carrier 418 for terminZl~ing~ protecting and mechanically fastening a plurality of wires
at one end of contacts 414.
Connector housing 412 comprises a front panel 420 having a standard modular
,iack opening 422 therein. A pair of side panels 424 and 426 depend rearwardly from
panel 420 on either side thereof and generally parallel to one another. Each panel 424
and 426 includes mounting holes 28 and 30 therein. A top panel 432 extends
rearwardly from panel 20 joining upper edges of panels 424 and 426. Panel 432
includes slopc members 434a and 434b which increasc the thickness of panel 432 and
termin~te in a pair of overhangs 436. Members 434 and overhangs 436 in combination
define a slot 442 for slidingly receiving an icon or insert 43. (the icons are illustrated
in FIGURES 8A-B in COnJunCtiOn with the description of a previous embodiment andare equally applicable here). Rearward of slot 442 is a panel receiving slot 444 which
is defined by the rearward of extreme member 434b, chamfer 446 (on the cap 416
which is more fully discussed hereinafter) and by removal of m~t~rizll from side panels
424 and 426. Housing 412 further includes a bottom panel 452~ which is disposed
opposite top panel 432 and which also extends rearwardly from front panel 420.
Bottom panel 452 is curved upwardly at a front end thereof to meet front panel 420.
Resilient member 454 depends downwardly of panel 452 and then approximately
follows the contours of 452 until it t~rrnin~tes in a panel receiving slot 456 at a front
end thereof which slot is adapted to engage a wall panel, plate or the like (see FIGURE
9 for a representative plate). Depending upwardly from a front edge of membcr 454 is
nub 455 to guide the insert of door 870 (more fully discussed hereinafter). Alsodepending upwardly from member 454 is rib 453 which engages and retains the door.
As illustrated in FIGURES 13A~ 13B, 14A and 14B, contact carrier 418
comprises a front generally L-shaped portion 462 which is receptive to a standard
modular outlet and includes a plurality of slots 464 therein for receiving contacts 414.
CA 02227~70 1998-01-22
W O 97/44862 PCTrUS97/05599
Slots 464 are defined at the front end of the lower leg portion 468 and in a partial
channel 470 in the front surface of upper leg portion 472. A second channel 474 is
defined in the back surface of upper leg portion 472. Channel 474 is defined by boxed
extensions 469 having chamfered edges 471 on a top edge thereof and filrther include
notches 473 which are coextensive with panel receiving slot 444 in housing 412 when
housing and carrier 418 are assembled. The front end of lower leg portion 468 isinclined to cooperate with the curved front end of panel 452 when contact carrier 418
is inserted in connector housing 412. To retain contact carrier 418 within connector
housing 412 arms 476, 478 are provided. Arms 476 and 478 each include an inclined
surface 480 to aid in the insertion of contact carrier 418 in connector housing 412 from
the rear thereof and ret~ining edges 482. Retaining edges 482 engage and are received
in holes 428 of side panels 424 and 426. A terrnination block portion 484 depends
rearwardly from the lower end of leg portion 472. Block portion 484 includes a
plurality of slots 486 at the lower portion thereof for receiving contacts 414. The
lower portion itself comprises three distinct surfaces on three distinct levels for
positioning of contacts. The surfaces are illustrated in figures 14b and 14c and are
identified by numerals 485a, 485b, and 485c. Each of the surfaces allow for
positioning of desired contacts. Furthermore the surfaces, because they are molded into
the carrier itself provide mechanical stability for the individual contacts in each of the
surfaces on which they are positioned. It should be understood that the slots 464 also
include three different levels of surfaces 485a, 485b and 485c which can be viewed in
figure 14c. Each slot 486 communicates with an opening 488 which extends throughblock portion 484, where corresponding contacts 414 pass through. A ramped surface
490 defining a retaining ledge 492 is defined at each side 494, 496 of block portion
484. A recess 498 is defined between block portion 484 and a downward extension
500 of lower leg portion 468. Recess 498 receives portions of contacts 414 when they
- are installed on contact carrier 418.
Depending ~ Ldly from block 484 is cable trap 700. Trap 700 includes side
walls 702. Side walls 702 filrther include undercut edges 704 to retain the t~rmin~fion
cap discussed hereunder. Body 706Of trap 700 which is disposed between sidewalls
CA 02227~,70 1998-01-22
W O 97/44862 PCT~US97/05599
-26-
702 includes a plurality, and preferably four protrusions 708 oriented on a rear section
thereof. These protrusions are adapted to meet tabs on the t~rrnin~tion cap, supporting
them, to prevent breaking thereof if the cable is pulled. Further wire retention is
provided by protuberances 710. The protuberances provide a form of mild retention or
strain relief only as to the central two pairs as will be appreciated by one of skill in the
art. Mild strain relief is provided because space was available and not because such
relief is necessary for the invention.
In communication with the members discussed above are several features of the
tcrmination cap 416 ofthis embodiment. As noted above, the protrusions 708 are
positioned imrnediately subjacently to the tabs 712 of cap 416. It should be noted that
because the tabs 712 are intended to be able to deflect in order to pass a twisted pair
past them, they can be broken by rough handling. In order to alleviate the possibility of
breakage, protrusions 708 support the same when cap 416is engaged with carrier 418.
The tabs 712 themselves are dependent from walls 714 which extend downwardly from
a lower surface 716 of cap 416. Discrete areas of lower surface 716, in combination
with latches 718, support tabs 728, and center wall 730 define grooves 732 as
illustrated in FIGIJRE 1 SA. Each of the four grooves 732is configured to accept one
twisted pair for passage through to the plurality of wire ret~ining slots 584 defined by
teeth 586. Teeth 586 each include ret~ining head 587 narrower at the extremity and
wider nearer the body of each tooth 586 as shown. This arrangement provides a
pathway for each untwisted wire the pathway being wider than the conductor itself and
narrower than the outside dimension of the insulation. Thus, some retention is
provided. It should be noted that for greater ease of insertion of each wire into each
slot 584 the head 587 includes angled surfaces 588. In order to assist the entry of wires
into slots 584, each twisted pair is ramped up from grooves 732 on ramps 733 to second
lower surface 734. Second lower surface 734 supports separation lugs 736 and also
provides IDC receptacles 738 for receiving IDC's after they are pressed onto individual
wires. It is preferable that the individual wires are not untwisted until beyond lugs 736
thus m~kin~ the smallest untwisted sections possible. Lugs 736 are four in nurnber and
function to separate four passageways for one twisted pair each. After the wires are
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
untwisted and laced into the ~lupllate slots, they are conse~uently positioned over
IDC receptacles 738 which places them over the desired IDC's extPn~in~ upwardly
from contact carrier 418.
As in the hereinbefore described embodiments the contacts in this embodiment
provide the same benefits and are arranged in subst~nti~lly the same way.
It should be noted that one of the benef1ts conferred by the arrangement of the
invention is that mass termination is rendered easier to the extent that the amount of
pressurc re~uired to so t~nnin~te the wires is reduced. The reduced pressure is
occasioned by a staggered height of the IDCs. Staggering the height causes a few wires
to t~rmin~t~ at a time while the termination cap 416 is being urged into engagement
with the jack 410.
Once the wires have been inserted into the slots of the termination cap as set
forth above, the wires are cut if they extend beyond the slots and the wires aret~nin~tecl onto respective insulation displacement tt-rrnin~l~ The wires are termin~t~cl
by inserting block 592 into channel 474 of contact carrier 418, thereby ~qligning the
termination cap 416 with the contact carrier 418, and pushing downwardly until the
insulation displacement terminals displace the insulation on the wires and electrically
connect with the conductive wire, ~i.e., a mass termin~tion). Termination cap 416 is
retained on contact carrier 418 by latch lips 740 the latches of which are subsequently
defeatable by conventional means if desired.
Referring to the inserts, it will be appreciated that the mounting thereof is
identical to the forgoing embodiment.
Referring to FIGURE 18, six modlllar outlets 1 Oa-10f are shown installed (in anside stackable manner) in corresponding openings 353, 355 of a wall plate 357. Slots
444 and 458 of each of the modular outlets receive corresponding edges of the wall
plate at the openings. As is clearly shown in this figure, the modular outlets provide for
- a gravity feed thereto, the advantages of which are well know, see for example, U.S.
Patent No. 5,362,254 to Siemon et al., which is incorporated herein by reference. It is
important to note that the jacks of the invention may be inserted either from the front or
rear of the plate to render in~ts~ tion an easier affair.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
-28-
As in the other embodiment, it is an important feature of the present invention
that while the modular outlet terminals are positioned in accordance with a standard
configuration, e.g., T568A, the insulation displacement t~rmin~l~ are configured to
improve wiring termin~tinn.
Also disclosed with respect to this outlet is a resilient door for the modular plug
opening. FIGURE 16A illustrates the entire assembly with the door 870 in place
whereas FIGURE 16B removes the door for closer inspection.
Referring to FIGUR~S 17A-D, door 870 includes plate 872 having pull tab 874
cxtending from one edge thereof and opening plug 876 protruding from a rear surface
thereof. Oppositely disposed on said plate from said tab is hinged attachment member
878 which is engageable between the bottom panel and the resilient member of thehousing 418. Hinged attachment member 878 includes narrowed band 880 extending
laterally across member 878 and immediately adjacent plate 872. Band 880 rendersdoor 870 easily operable. Member 878 further includes wedge 882 connected to band
880 and which communicates with the area defined between bottom panel 452 and
resilient member 454. Depression 881 is intended to engage rib 453 on member 454.
Channel 883 is provided to allow member 878 to align with nub 455 when being
inserted. Door 870 is constructed of a deforrnable material and preferably of neoprene
material. The door must be inserted into the housing only after the outlet is inserted
into the wall plate. Otherwise because of the reci~t~n~e of the door the resilient
member 454 will be prevented from deforming sufficiently to enable the outlet to be
inserted into the plate.
Referring to FIGURE 19, a shield 760 is illustrated in an extracted form from
the contact carrier 418 illustrated in this disclosure. The shield is employable with all
of the jacks presented herein, if desired, by snapping the shield in the desiredconnection. The shield provides a single continuous low impedance connection for the
incoming cable shield and outgoing cable shield, not shown. As will be appreciated by
those skilled in the art a low impedance path which avoids the current carrying
drawbacks of having a multiple connection and, therefore, higher impedance pathway.
CA 02227~70 1998-01-22
WO 97/44862 PCT/US97/05599
-29-
The shield of the invention includes a pair of fingers 762 ~t~n-ling from a
frame 764 and which are the contact points for the shield contacts on the plug to be
inserted in the jack of the invention. In order to create a solid connection, finger ends
766 include an inwardly proiecting bend portion which will act to tighten a subsequent
connection. Frame 764 further includes grounding tab 768 which may optionally beconnected to a grounded housing, not shown. Tab 768 is configured for a standardfemale terminal, not shown. Alternatively, ~ssllmin~ grounding is desired, uprights 770
having angled ends 772 extend from a top edge of frame 764 to provide grounding on a
grounded face plate. In this alternative, ends 772 nestle in notches 473 on carrier 418
and contact the face plate when the Jack is inserted into the same.
The rear edge of frame 764 supports rearwardly extending members 774 which
t~rmin~te rearwardly in end plates 776. To provide sufficient room for contact carrier
418 which when engaged is located between members 774, each member contains two
bend areas. Forward bend area 778 widens the (1imen~ion between members 774 and
rearward bend area 780 narrows the dimension to substantially the same dimension as
frame 764. Plates 776 define the contact area for the incoming cable shield.
Referring to FI(:~URE 20, a partially exploded view of the invention with the
shield in place. Positioned in this manner, ends 772 are visible in notches 473. Perusal
of the figure will provide a complete unders~n~ling of the engagement of shield 760
with carrier 418. FIGURES 21 and 22 provide views where the entire outlet is
assembled.
In yet another embodiment of the invention, referring to FIGURES 23-25, a
straight outlet is illustrated. The straight outlet 810 employs the contact carrier 418 and
thc termination cap 416 of the previous embodiment but utilizes a housing 812
constructed somewhat differently than those previously discussed.
In general, housing 812 is of similar configuration, having a front panel 820
with a standard modular jack opening 822 therein and two side panels 824 and 826which define holes 828 and 830. Top panel 832, bottom panel 852 differ in structure
and orientation from the 412 embodiment. For clarity of drawings all of the parts of
CA 02227~70 1998-01-22
W O 97/44862 pcTrus97lo5599
-30-
this embodiment employ identical suffix numerals but it should be appreciated that the
whole outlet 810is used upside down from the previous embodiments.
Top panel 832 includes angled stops 834A and 834B which ramp toward one
another and provide opposed stop surfaces defining a panel receiving slot 844. Slot
844is positioned much more closely to front panel 820 than slot 444is to panel 420 in
the previous embodiment because the outlet 810is not inf~ncled to provide gravity feed.
Bottom panel 852is angled upward to meet front panel 820 similarly to panel
452 but adjacent the interface between panel 852 and 820 an icon groove 85 lA isdisposed and is coplanar with icon groove 85 lB disposed upon resilient member 854
depending from bottom panel 852. As with dependent resilient member 454, member
854 includes panel receiving slot 856. It will be appreciated by those skilled in the art
that oncc panel receiving slot 844 and panel receiving slot856 are engaged with a
panel, the introduction of icon 43 into icon grooves 851 A and 851 B prevents deflection
of member 854 thus locking the outlet into the panel. The outlet then cannot be
removed without first removing the icon.
It is important to understand that each of the embodiments whether shielded or
not, desired or not are side stackable in a single opening composed of multiples of an
industry standard size. This provides space ef~lciency thus increasing the aesthetic
appeal of a multiple outlet wall mount and meeting the high outlet-density demands of
certain appl;cations. A wall plate opening may have a range of widths to accommodate
a desired number of outlets.
Moreover, all of the embodiments herein are configured for engagement with
the wall plate from either front or rear which increases connection options and avoids
the common drawback of connection from the rear of the plate only to require that all
the cables be "stuffed" into the junction box for the plate to be secured to the wall.
Referring to FIGURES 26-28, a modular outlet in accordance with the present
invention is shown generally at 900. Modular outlet 900 is the same as modular outlet
410 of FIGURES 1 1 A-B, except for the connector housing configuration and the
addition of a door, as described more fully below.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/~5599
-31-
Referring also to FIGURES 29 and 30, the connector housing 912 comprises a
front panel 920 having a standard modular outlet opening 922 therein. A door 914,
described more fùlly hereinbelow, is mounted on housing 912 at opening 922. A pair
of side panels 924 and 926 depend rearwardly from panel 920. Each panel 924 and 926
has mounting holes 928 and 930 therein for retention of the contact carrier, as
described hereinbefore. A top panel 932 extends rearwardly from panel 920 joining
upper edges of panels 924 and 926. Housing 912 further includes a bottom panel 952,
which is disposed opposite top panel 932 and which also extends rearwardly from front
panel 920. A resilient member 954 depends from the rearward end of panel 952 andl O thcn extends approximately parallel thereto to engage a wall panel, plate or the like
(e.g., see FIGURE 9 for a l~lt; ,t;llL~Live plate) when modular jack 900 is installed in
the same.
Connector housing 912 further includes notches 976 and 978 at the corners
defined by panels 924, 926 and 952. Each notch 976 and 978 has an opening 980
therein. Each notch 976 and 978 has a sloped lower surface 982 and a rear upright
surface 984 with an accurate surface 986 therebetween. Each notch 976 and 978
also has an inside surface 988 with a protrusion 9~0 extending therefrom.
Referring also to FI~URES 31 and 32, door 914 comprises a first end portion
992, a second end portion 994, and a middle potion 996 disposed therebetween.
Portion 992 has a generally rectangular shape comprising opposing ends 998, 1100,
opposing sides 1102, 1104 and opposing sides 1106, 1108. A tab 1110 (for use in
opening and closing door 914) depends from end 1100 and side 1106. Further, a
portion of end 1100 extends beyond side 1108 forming an overhang which defines aretaining edge 1112. Portion 994 comprises a rectangular member having opposing
sides 1114, 1116,opposingends 118, 1120andopposingsides 1122, 1124. Apairof
arms 1126, 1128 depend angularly away from side 1124. Each arrn t~rrnin~tes in a~ corresponding cylindrically shaped member 1130, 1132. A semi-circular protrusion
1134 depends inwardly from the inwardly end of each member 1130 and 1132. Also,
adjacent members 1130 and 1132 are protrusions 1136 which depend inwardly from
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/Q5S99
the inwardly surface of each arm 1126 and 1128. Further, a portion of side 116 extends
beyond side 1122 forming an overhang which defines a retaining edge 1138.
Portion 996 has a generally rectangular shape comprising opposing ends 1140,
1142, opposing sides 1144, 1146 and opposing sides 1148, 1150. Resistant arms 1152
and 1154 depend downwardly from end 1142 and side 1146. Each arrn 1152, 1154
termin~tes at a ramped surface 1156 (lefinin~ a ret~ining edge 1158. End 1142 isconnected at opposing sides to corresponding end 998 of portion 992 and side 1114 of
portion 994.
A channel defined by side 1108 and edge 1112 of portion 992, surface 1142 of
portion 996, and side 1122 and edge 1138 slidingly receives an icon or insert 1160,
such as shown in FIGURES 8A-B.
Protrusions 1134 and door 914 are received in openings or recesses 980 of
conncctor housing 912 and members 1130 and 1132 are received in notches 976 and
978, thereby ret~inin~ door 914 on housing 912. It is an important feature of the
present invention that protrusions 1136 of door 914 bear against surface 988 of the
notches (in connector housing 12) and with protrusions 990 on surface 988 causing
door 914 to be retained in an open pOSitiOll and closed position, depending on which
side of protrusions 990 the protrusions 1136 are disposed. As door 914 is moved
between these positions, protrusions 1136 ride over protrusions 99Q. Further, inthe closed position, edges 1158 of arms 1152 and 1154 engage the inside surface of
panel 920, to retain door 114 in the closed position when that particular port is not in
use.
~eferring to FIGURES 33 and 34, a modular outlet in accordance with an
alternate embodiment of the present invention is shown generally at 1200. Modular
1200 is the same as modular outlet 810 of FIGURES 24, except a door holder 1202 is
inserted in place of the icon and a door 1204 is supported thereon. Door 1202
(FIGURES 35 and 36) is the sarne as door 914 of FIGURES 31 and 32 except for theshape of protrusions 1136', which are semi-circular in this embodiment. An icon is
received in door 1202 in the sarne manner as described above.
CA 02227~70 1998-01-22
W O 97/44862 PCT~US97/05599
Referring also to FIGURES 37-40, door holder 1202 is generally shown. Door
holder 1202 has a generally rectangular shaped base 1204 with a V-shaped notch 1206
forrned at opposing ends thereof. Base 1204 has a raised region 1208 depending from
one side thereof. The longitudinal sides 1210 of raised region 1208 are sloped
downwardly to meet base 1204. Recesses or openings 1212 are formed at opposing
ends of raised region 1208, adj acent the vortex of each notch 1206. Corner notches
1214, 1216, 1218 and 1220 are formed at each of the four corners of raised region
1208.
Sides 1222 and 1224 are received in icon grooves 851a and b (FIGURE 25),
whereby door holder 1202 is retained in the same fashion the icon is retained in the
embodiment of FIGURE 25.
Protrusions 1134Ofdoor 1202arereceivedinopeningsorrecesses 1212Of
door holder 1202 and members 1130 and 1132 are received in notches 1206. It is an
important feature of the present invention that protrusions 1136' of door 1202 bear
againstraisedportion 1208. Protrusions 1136' of door 1202whenreceivedinnothces
1216 and 1218 retain door 1202 in a first (e.g., open) position and in notches 1214 and
1220 retain door 1202 is a second (e.g., closed~ position. As door 1202 is movedbetween these positions, protrusions 1136' ride over the end surfaces 1226 and 1228 of
raised portion 1208.
While preferred embodiments have been shown and described, various
modifications and substitutions may be made thereto. Accordingly, it is to be
understood that the present invention has been described by way of illustrations and not
limitation.
~ii'hat is claimed is:
